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Injection molding is one of the most widely used processes for making plastic components because it makes it easier to produce huge quantities of similar parts. Obtaining the mold and utilizing it to make components are the only two stages involved in the very basic injection molding process. Furthermore, injection molding is nearly always the least expensive method for producing parts in medium- to high-volume production.
Table of Contents
What is Injection Molding?
Many different industries employ injection molding, a highly versatile manufacturing technique, to make a wide range of plastic parts and components. Molten material, normally thermoplastics, is injected into a mold cavity in this procedure. However, the careful selection of the injection mould material is quite crucial to the end product’s quality and success. When trying to select the perfect material, factors such as desirable qualities, performance needs and environmental issues are taken into account. The flexibility, strength and chemical and heat resistance of the material all have a great impact the durability and functionality of the end product.
Types of Injection Molding Material
There are many types of materials used in injection moulding, with over 85,000 commercial plastic material options and 45 polymer families. The thermosets and thermoplastics are the two main categories into which these polymers may be divided.
High-density polyethylene (HDPE) and low-density polyethylene (LDPE) are the two most widely used plastic kinds. High ductility levels, exceptional tensile strength, robust impact resistance, resistance to moisture absorption, and recyclability are just a few benefits that polyethylene has to offer.
Additional frequently utilized injection-molded polymers consist of:
Acrylonitrile Butadiene Styrene (ABS)
Industry uses this strong, impact-resistant injection mould material extensively. ABS has excellent dimensional stability, low shrinkage rates and resistance to acids and bases.
Polycarbonate (PC)
Good dimensional stability and low shrinkage characterize this robust, impact-resistant injection mould material. PC is a transparent plastic that comes in several optically clear grades and has strong heat resistance in addition to a high aesthetic finish.
Aliphatic Polyamides (PPA)
PPA, often known as nylons, come in a variety of forms and each offers benefits of its own. In general, this injection mold material is resistant to strong acids and bases, high temperatures and chemicals. They also offer excellent strength and temperature resistance. Certain nylons have strong impact strength, good hardness and stiffness along with resistance to abrasion.
Polyoxymethylene (POM)
This injection mould material, often referred to as acetal, is very strong, stiff, hard and durable. In addition, it resists hydrocarbons and organic solvents and has high lubricity. Certain applications can benefit from good slipperiness and elasticity.
Polymethyl Methacrylate (PMMA)
PMMA, commonly referred to as acrylic, is an injection mold material that has excellent scratch resistance, high gloss and optical qualities. For geometries with thin and narrow sections, it also provides little sink and less shrinkage.
Polypropylene (PP)
At the instance of propylene homopolymer, this low-cost resin material might be fragile at cold temperatures yet offers good impact resistance in certain grades. While PP is flexible, wear-resistant, and capable of extremely high elongation, copolymers offer superior impact resistance. Additionally, this injection mould material is resistant to both acids and bases.
Polybutylene Terephthalate (PBT)
PBT’s excellent electrical qualities make it perfect for use in power components and automotive settings. Depending on the glass fill, the strength of this injection mould material varies from moderate to high; the unfilled grades are robust and flexible. In addition to displaying fuels, oils, fats, and other solvents, PBT also resists taste absorption.
Polyphenylsulfone (PPSU)
Polyphenylsulfone (PSSA) is another injection mould material. In addition to having excellent toughness, temperature and heat resistance, and dimensional stability, PPSU is resistant to radiation sterilization, alkalis and mild acids.
Polyether Ether Ketone (PEEK)
Excellent strength and dimensional stability, exceptional chemical resistance, heat resistance, and flame retardancy are all provided by this high-temperature, high-performance injection mold material.
Polyetherimide (PEI)
PEI (also known as Ultem) is the last material used for injection moulding on our list. This injection mould material has good strength, dimensional stability, chemical resistance and high temperature and flame resistance.
Material Used for Injection Molding
Various variables, including product needs, desired qualities, financial concerns and environmental effects, influence the choice of injection molding material. There are two primary types of materials that are utilized in injection molding:
Virgin Plastic
New, unused plastic resin made especially for injection molding is referred to as virgin plastic. It provides a large selection of material alternatives, excellent performance, and consistent quality. Virgin plastic is frequently used when certain performance standards or legal compliance are needed.
Recycled Plastic
As the name implies, recycled plastic is created by processing post-consumer or post-industrial plastic waste to create new pellets that are ready for injection molding. Recycled plastic has a number of advantages, including less of an adverse effect on the environment, resource conservation, and financial savings.
Material Used for Injection Molding
One major benefit of injection molding plastic materials is its ability to make huge quantities of parts by scaling up manufacturing. The price of production is extremely inexpensive after the initial expenses of the design and the molds are paid. Producing additional components results in a decrease in manufacturing costs.
By eliminating superfluous material using CNC machining, a typical production technique, injection molding also results in less waste. Although this is the case, injection molding does generate waste; this waste mostly comes from the sprue, the runners, the gate locations and any overflow material (commonly known as “flash”) that seeps out of the component cavity.
The capacity to produce a large number of identical parts, which promotes part uniformity and dependability in high volume manufacturing, is the last benefit of injection molding.
The Best Injection Molding Plastic Materials Manufactured by Exirpolymer
ExirPolymer is a leading manufacturer of recycled plastic pellets for injection molding applications. Our area of expertise lies in manufacturing high-quality recycled plastic materials that meet industry standards and customer requirements. Numerous recycled plastic choices are available from ExirPolymer, such as ABS, polypropylene, and polyethylene.
To guarantee constant quality and performance, our recycled plastic pellets are meticulously treated and evaluated. ExirPolymer creates recycled polymers with qualities similar to virgin plastic using sophisticated recycling procedures, which makes them appropriate for a range of injection molding projects.
Here are the products used for this method:
Recycled PP Granules
Recycled PP Granules share many of the same characteristics as virgin PP resin. Their robust strength, exceptional chemical resistance, and high melting point make them suitable for a wide range of applications. These granules can be used in blow molding, extrusion, injection molding and other plastic processing techniques. PP 8000-F Polypropylene Granules are a premium product from this type of plastic materials.
Recycled Polystyrene Granules
Recycled Polystyrene Granules, a synthetic polymer that is widely utilised and adaptable, are very tiny particles. Polystyrene is derived from styrene, a petroleum-based liquid monomer that is polymerized to become a hard, solid material. The PS 7000-F product is a pure polystyrene granule made from recycled HIPS that has a striking similarity to virgin petrochemical materials. This product is very suitable for injection molding.
ABS Granules
Because of their exceptional strength, resilience to impact, and stiffness, ABS plastic granules are a great choice for structurally robust products. Because of their low melting point, they are simple to work with and appropriate for injection molding and 3D printing. They don’t alter in size in response to variations in temperature or other influences. ABS Plastic Granules 6100 Injection Grade is one product to mention an example from this category.
Plastic Compounds
Our company’s plastic compounds are appropriate for injection molding as well. For example, the 80 series PP compound (polypropylene + CACO3) is a robust and durable thermoplastic. The outstanding features of PP compounds series 80 include uniform distribution of CACO3 on the polymer surface, control over shrinkage and non-stickiness of the product during the injection process due to standard compounding, and cost-effectiveness without losing quality characteristics. It can be used for all injection molded parts.
ExirPolymer: Manufacturer of recycled plastic pellets for injection molding
Aside from cost savings and regulatory compliance, using recycled materials for injection molding has other advantages for the environment and performance. Producing premium recycled plastic pellets for injection molding is the area of expertise for businesses such as ExirPolymer.
We guarantee that producers may obtain dependable and eco-friendly materials for their injection molding requirements because of our dedication to sustainability and excellence. Manufacturers may lessen their environmental effect, satisfy sustainability targets and promote a circular economy without sacrificing the quality or functionality of their goods by selecting recycled plastic pellets from ExirPolymer.
